CN102282007A - Process for producing tubular structure made of fiber-reinforced resin and tubular structure made of fiber-reinforced resin - Google Patents
Process for producing tubular structure made of fiber-reinforced resin and tubular structure made of fiber-reinforced resin Download PDFInfo
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- CN102282007A CN102282007A CN2009801548415A CN200980154841A CN102282007A CN 102282007 A CN102282007 A CN 102282007A CN 2009801548415 A CN2009801548415 A CN 2009801548415A CN 200980154841 A CN200980154841 A CN 200980154841A CN 102282007 A CN102282007 A CN 102282007A
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- 229920005989 resin Polymers 0.000 title claims abstract description 81
- 239000011347 resin Substances 0.000 title claims abstract description 81
- 238000000034 method Methods 0.000 title claims abstract description 11
- 229920000049 Carbon (fiber) Polymers 0.000 claims abstract description 123
- 239000004917 carbon fiber Substances 0.000 claims abstract description 123
- VNWKTOKETHGBQD-UHFFFAOYSA-N methane Chemical compound C VNWKTOKETHGBQD-UHFFFAOYSA-N 0.000 claims abstract description 73
- 238000011144 upstream manufacturing Methods 0.000 claims abstract description 35
- 238000000465 moulding Methods 0.000 claims abstract description 29
- 239000007787 solid Substances 0.000 claims abstract description 22
- 239000002759 woven fabric Substances 0.000 claims abstract description 16
- 239000004744 fabric Substances 0.000 claims description 104
- 239000000835 fiber Substances 0.000 claims description 23
- 238000004519 manufacturing process Methods 0.000 claims description 22
- 230000003014 reinforcing effect Effects 0.000 claims description 12
- 238000005520 cutting process Methods 0.000 claims description 9
- 230000002787 reinforcement Effects 0.000 claims description 8
- 230000033001 locomotion Effects 0.000 claims description 6
- 230000000149 penetrating effect Effects 0.000 claims description 3
- 238000013007 heat curing Methods 0.000 claims 1
- 238000010438 heat treatment Methods 0.000 abstract description 8
- 238000001029 thermal curing Methods 0.000 abstract 1
- 238000002591 computed tomography Methods 0.000 description 9
- 239000007788 liquid Substances 0.000 description 9
- 238000005470 impregnation Methods 0.000 description 8
- 229920001187 thermosetting polymer Polymers 0.000 description 7
- 230000000694 effects Effects 0.000 description 6
- 230000035515 penetration Effects 0.000 description 6
- 238000002601 radiography Methods 0.000 description 5
- 238000004804 winding Methods 0.000 description 5
- 230000005540 biological transmission Effects 0.000 description 4
- 238000003384 imaging method Methods 0.000 description 4
- 239000003822 epoxy resin Substances 0.000 description 3
- 229920000647 polyepoxide Polymers 0.000 description 3
- 229920006337 unsaturated polyester resin Polymers 0.000 description 3
- 229920001567 vinyl ester resin Polymers 0.000 description 3
- 239000004952 Polyamide Substances 0.000 description 2
- 230000002411 adverse Effects 0.000 description 2
- 230000006835 compression Effects 0.000 description 2
- 238000007906 compression Methods 0.000 description 2
- 239000004745 nonwoven fabric Substances 0.000 description 2
- 229920002647 polyamide Polymers 0.000 description 2
- 229920000728 polyester Polymers 0.000 description 2
- 239000004372 Polyvinyl alcohol Substances 0.000 description 1
- 230000004913 activation Effects 0.000 description 1
- -1 and preferably Polymers 0.000 description 1
- 229920006231 aramid fiber Polymers 0.000 description 1
- 238000005452 bending Methods 0.000 description 1
- 230000009286 beneficial effect Effects 0.000 description 1
- 238000010276 construction Methods 0.000 description 1
- 239000006185 dispersion Substances 0.000 description 1
- 230000002708 enhancing effect Effects 0.000 description 1
- LNEPOXFFQSENCJ-UHFFFAOYSA-N haloperidol Chemical compound C1CC(O)(C=2C=CC(Cl)=CC=2)CCN1CCCC(=O)C1=CC=C(F)C=C1 LNEPOXFFQSENCJ-UHFFFAOYSA-N 0.000 description 1
- 230000002401 inhibitory effect Effects 0.000 description 1
- 238000003780 insertion Methods 0.000 description 1
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Images
Classifications
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C70/00—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts
- B29C70/04—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts comprising reinforcements only, e.g. self-reinforcing plastics
- B29C70/28—Shaping operations therefor
- B29C70/40—Shaping or impregnating by compression not applied
- B29C70/50—Shaping or impregnating by compression not applied for producing articles of indefinite length, e.g. prepregs, sheet moulding compounds [SMC] or cross moulding compounds [XMC]
- B29C70/52—Pultrusion, i.e. forming and compressing by continuously pulling through a die
- B29C70/521—Pultrusion, i.e. forming and compressing by continuously pulling through a die and impregnating the reinforcement before the die
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C70/00—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts
- B29C70/04—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts comprising reinforcements only, e.g. self-reinforcing plastics
- B29C70/06—Fibrous reinforcements only
- B29C70/10—Fibrous reinforcements only characterised by the structure of fibrous reinforcements, e.g. hollow fibres
- B29C70/16—Fibrous reinforcements only characterised by the structure of fibrous reinforcements, e.g. hollow fibres using fibres of substantial or continuous length
- B29C70/22—Fibrous reinforcements only characterised by the structure of fibrous reinforcements, e.g. hollow fibres using fibres of substantial or continuous length oriented in at least two directions forming a two dimensional structure
- B29C70/222—Fibrous reinforcements only characterised by the structure of fibrous reinforcements, e.g. hollow fibres using fibres of substantial or continuous length oriented in at least two directions forming a two dimensional structure the structure being shaped to form a three dimensional configuration
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29K—INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
- B29K2707/00—Use of elements other than metals for preformed parts, e.g. for inserts
- B29K2707/04—Carbon
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29L—INDEXING SCHEME ASSOCIATED WITH SUBCLASS B29C, RELATING TO PARTICULAR ARTICLES
- B29L2023/00—Tubular articles
- B29L2023/005—Hoses, i.e. flexible
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- Engineering & Computer Science (AREA)
- Chemical & Material Sciences (AREA)
- Composite Materials (AREA)
- Mechanical Engineering (AREA)
- Textile Engineering (AREA)
- Moulding By Coating Moulds (AREA)
- Reinforced Plastic Materials (AREA)
- Apparatus For Radiation Diagnosis (AREA)
Abstract
A process for producing a tubular structure made of a fiber-reinforced resin is provided in which a drawing operation in the molding of a molding intermediate is facilitated and wall thickness can be inhibited from increasing. A strength improvement can also be attained. Also provided is a tubular structure made of a fiber-reinforced resin. Solid grip parts (23) are formed integrally with both width-direction edges of a tubular intermediate molding (15), each grip part (23) protruding outward in the width direction and continuously extending in the lengthwise direction. The inner surfaces of a pair of upper and lower holding dies (11, 12) are brought into contact with the surfaces of the intermediate molding (15) which has been cured. The grip parts (23) are sandwiched between the holding dies (11, 12) and this intermediate molding (15) in a compressed state is moved downstream over a given distance. A continuous carbon-fiber woven fabric including carbon fibers as the warp and impregnated with an uncured resin is inserted into the tubular molding space between a molding die and a core, and is drawn over a given distance from the upstream side to the downstream side while heating the impregnated woven fabric and applying a tension thereto. The resultant tubular intermediate molding (15) obtained through thermal curing is successively conveyed downstream and cut into a given length.
Description
Technical Field
The present invention relates to a method for producing a cylindrical body made of fiber-reinforced resin and a cylindrical body made of fiber-reinforced resin, and more particularly, to a method for producing a cylindrical body made of fiber-reinforced resin and a cylindrical body made of fiber-reinforced resin, which can facilitate drawing work in molding an intermediate body for molding, and can suppress increase in wall thickness and improve strength.
Background
Conventionally, a cylindrical body made of fiber-reinforced resin has been used as a top plate for radiography. In the production of such a tubular body, a core is inserted into a molding die, a long carbon fiber woven fabric impregnated with uncured resin is inserted into a tubular molding space formed between the molding die and the core, and a predetermined length is drawn in the order from the upstream side to the downstream side while applying tension, whereby a tubular intermediate molded body is molded and heat cured, and then the cured intermediate molded body is sequentially conveyed to the downstream side to be cut into a predetermined length (see patent document 1).
In this manufacturing process, the drawing operation is performed in a state where the solidified intermediate formed body is held by being sandwiched from above and below. When a long carbon fiber woven fabric impregnated with an uncured resin is inserted into a forming die and drawn, a certain degree of drawing force is required, and accordingly, it is necessary to hold an intermediate formed body in a state of being sandwiched from above and below.
Since the intermediate formed body has a hollow structure, it is easily deformed by the pressure held by the nip during the drawing operation. In order to prevent such deformation, it is necessary to increase the thickness of the hollow portion of the intermediate formed body, and therefore the produced fiber-reinforced resin cylindrical body has a problem in that it is manufactured to have a thickness greater than that actually required.
For example, when the manufactured tubular body is applied to a top plate for CT or X-ray imaging, since the thickness is increased more than necessary, the X-ray transmission loss increases, and a problem arises that precise image data cannot be obtained. Further, if the pressure for sandwiching and holding the intermediate formed body is small, the drawing force cannot be increased, and therefore the drawing operation becomes difficult. In addition, it is difficult to increase the degree of collimation R of the warp yarn of the fiber-reinforced resin, and it is not preferable to increase the strength of the manufactured tubular body.
Patent document 1: japanese patent laid-open publication No. 2003-319936
Disclosure of Invention
The invention aims to provide a method for manufacturing a fiber reinforced resin cylindrical body and the fiber reinforced resin cylindrical body, which can facilitate drawing operation during forming of a forming intermediate, inhibit increase of wall thickness and improve strength.
In order to achieve the above object, a method for manufacturing a cylindrical body made of fiber-reinforced resin according to the present invention is a method for manufacturing a cylindrical body made of fiber-reinforced resin, in which a core is inserted into a space linearly penetrating a molding die, a long carbon fiber woven fabric in which at least carbon fibers are impregnated with uncured resin is inserted into a cylindrical molding gap formed between the molding die and the core, and a cylindrical intermediate molded body is formed by drawing from an upstream side to a downstream side by a predetermined length in order to make the outer plate and the inner plate face each other with a gap therebetween, and both end portions in a width direction of each other are connected to each other, and after the intermediate molded body is heated and cured, the cured intermediate molded body is sequentially conveyed to the downstream side and cut by a predetermined length to manufacture a cylindrical body, wherein a degree of alignment R of the warp fibers defined with a center line passing through a center in the width direction of the cylindrical body as a reference is 90%, wherein, in the molding of the intermediate molded body, solid grip portions that protrude outward in the width direction and are continuous in the longitudinal direction are integrally formed at both ends in the width direction of the intermediate molded body, inner surfaces of a pair of upper and lower holding dies are brought into contact with the surface of the intermediate molded body so as to cover the surface of the solidified intermediate molded body, the pair of upper and lower holding dies are moved to the downstream side by a predetermined length in a state where the solidified grip portions are sandwiched by the pair of upper and lower holding dies and compressed, and a new carbon fiber woven fabric is inserted into the molding gap and is drawn from the upstream side to the downstream side by the predetermined length while applying tension.
The solidified gripping portion may be moved downstream by a predetermined length while being compressed by a pair of upper and lower holding dies, and then the gripping portion held by the pair of upper and lower holding dies may be cut. The portion where the grip portion is cut may be reinforced by a reinforcing member made of fiber-reinforced resin. Two of the upper and lower pair of holding dies may be arranged at an interval in the moving direction of the intermediate formed body, and a first moving step and a second moving step may be alternately performed to insert a new carbon fiber woven fabric into the forming gap and draw a predetermined length from the upstream side to the downstream side while applying tension, wherein in the first moving step, the predetermined length is moved to the downstream side in a state where the solidified gripping portions of the intermediate formed body are sandwiched and compressed by the upper and lower pair of holding dies on the upstream side, and the predetermined length is moved to the upstream side in a state where the solidified gripping portions of the intermediate formed body are not sandwiched by the upper and lower pair of holding dies on the downstream side, and in the second moving step, the predetermined length is moved to the downstream side in a state where the solidified gripping portions of the intermediate formed body are sandwiched and compressed by the upper and lower pair of holding dies on the downstream side, respectively, while holding dies in a pair from top to bottom on the upstream sideThe intermediate formed body is moved upstream by a predetermined length without sandwiching the solidified holding portion of the intermediate formed body. The tension of the carbon fiber fabric inserted in the forming gap is, for example, 5N/mm2Above 980N/mm2The following.
The present invention provides a fiber-reinforced resin tubular body in which outer and inner plates of long dimensions are arranged facing each other with a gap therebetween and both ends in the width direction of the outer and inner plates are connected to each other, the outer and inner plates are made of a fiber-reinforced resin having a carbon fiber fabric in which at least warp yarns are carbon fibers as a main reinforcement, and the warp yarns are linearly arranged in parallel in the longitudinal direction of the outer plate and the inner plate, the degree of collimation R of the warp yarn is more than 90% based on the central line passing through the center of the width direction of the cylindrical body, wherein the cylindrical body has solid grip portions at both ends in the width direction thereof, the grip portions projecting outward in the width direction and continuing in the longitudinal direction, the grip portion is integrally formed with the fiber-reinforced resin, and solid portions having a width-directional length of 1.0% to 8.0% of the width of the tubular body are formed at both ends of the tubular body in the width direction.
In the fiber-reinforced resin tubular body of the present invention, both ends in the width direction of the tubular body are formed by cutting a solid gripping portion which is integrally formed in advance with the fiber-reinforced resin, protrudes outward in the width direction, and is continuous in the longitudinal direction.
In the tubular body of the present invention, the portion of the grip portion subjected to the cutting process may be reinforced by a reinforcing member made of a fiber-reinforced resin. The carbon fiber fabric may be a cord fabric having a weft density of 1 piece/cm or less, and the weft of the cord fabric is made of an organic fiber having a weft density of 50dtex or more and 350dtex or less. The cord fabric may be stacked in plural, and an all-carbon fiber fabric formed of carbon fibers in both warp and weft may be inserted between any two cord fabrics. The all-carbon fiber fabric may be provided so as to straddle both sides of the outer and inner plates. Alternatively, the all-carbon fiber fabric having a wider width with respect to the plate width may be inserted into one of the outer and inner plates, and both ends of the all-carbon fiber fabric may be folded back onto the other plate side.
According to the present invention, since the solid grip portions that protrude outward in the width direction and are continuous in the longitudinal direction are integrally formed at both ends in the width direction of the cylindrical intermediate formed body that connects both ends in the width direction of the outer panel and the inner panel that are arranged facing each other at a pitch, and the grip portions are formed solid, the cured grip portions can be firmly sandwiched by the pair of upper and lower holding dies. Thus, drawing work can be performed by holding only the solid gripping portion with a sufficiently large pressure without applying an excessive pressure to the hollow-forming portion of the solidified intermediate formed body.
Thus, the intermediate formed body can be formed into a hollow portion without considering the strength when it is sandwiched and held by the pair of upper and lower holding dies, and therefore the thickness can be set to a minimum. Meanwhile, when the manufactured tubular body is applied to a CT or a general top plate for X-ray radiography, the transmission loss of X-rays can be reduced, and more precise image data can be obtained.
Further, since the solidified gripping portion can be compressed and held by a large pressure, the drawing force can be increased as compared with the conventional art, and therefore the drawing operation is facilitated. Meanwhile, it is easy to raise the degree of collimation R of the warp of the carbon fiber fabric to 90% or more, which is advantageous for enhancing the strength of the manufactured tubular body.
Drawings
FIG. 1 is a schematic view illustrating an overall process for producing a cylindrical body made of a fiber-reinforced resin according to the present invention;
fig. 2 is a side view illustrating the drawing apparatus of fig. 1;
FIG. 3 is a cross-sectional view taken along A-A of FIG. 2;
FIG. 4 is a cross-sectional view taken along line B-B of FIG. 2;
fig. 5 is a side view illustrating a drawing operation (first moving step) by the drawing apparatus of fig. 2;
fig. 6 is a side view illustrating a drawing operation (second moving step) by the drawing apparatus of fig. 2;
FIG. 7 is a cross-sectional view illustrating an embodiment of the cartridge of the present invention;
FIG. 8 is a top view of FIG. 7;
fig. 9 is a cross-sectional view illustrating another embodiment of the cartridge of the present invention;
fig. 10 is a sectional view illustrating another embodiment of the cartridge of the present invention;
FIG. 11 is an explanatory view of a method for measuring the degree of collimation R of a warp yarn according to the present invention;
FIG. 12 is a cross-sectional view illustrating the structure of an outer plate and an inner plate of a tubular body according to the present invention;
FIG. 13 is a cross-sectional view illustrating another structure of an outer plate and an inner plate of a tubular body according to the present invention;
fig. 14 is a sectional view illustrating the structure of the cylindrical body of the present invention.
Description of the reference numerals
1: manufacturing apparatus
2: resin liquid tank
4: forming die
4 a: mold core
5: drawing device
5a, 5 b: slider for a slide fastener
6: up-and-down motion cylinder
11: upper holding die
12: lower holding die
15: intermediate formed body
16: heating furnace
17: cutting machine
20: top board (Cylinder shape body)
21: outer plate
22: inner plate
23: gripping part
23 a: reinforcing element
24: cord fabric
25: all-carbon fiber fabric
26: unidirectional carbon fiber sheet
Detailed Description
Hereinafter, a method for producing a fiber-reinforced resin cylindrical body and a fiber-reinforced resin cylindrical body according to the present invention will be described in detail with reference to the drawings. In the embodiment, a case where the cylindrical body is applied to a top plate for CT (computed tomography) or general X-ray imaging will be described as an example.
As illustrated in fig. 7 and 8, a top plate (tubular body) 20 of the present invention is made of a reinforced fiber resin, and has a hollow shape formed by arranging long outer plates 21 and long inner plates 22 facing each other with a space therebetween and connecting both width-direction end portions of each other. The outer panel 21 and the inner panel 22 are made of fiber-reinforced resin having a carbon fiber fabric, in which at least warp yarns are carbon fibers, as a main reinforcement, and the warp yarns are arranged in a straight line shape parallel to each other in the longitudinal direction of the outer panel 21 and the inner panel 22. The degree of collimation R of the warp yarn, which is defined as a center line CL passing through the center of the top sheet 20 in the width direction, is 90% or more. In fig. 8, the warp yarns are shown by solid lines and the weft yarns are shown by broken lines, and the warp yarns and the weft yarns are schematically shown.
In the present invention, the degree of collimation R is an average value of the sum of values calculated by measuring ten points on one side of each top plate 20 by the following measurement method.
That is, in each of the regions divided into ten equal parts in the width direction by the outer panel 21 and the inner panel 22 of the top panel 20, when a center line passing through the center in the width direction of the tubular body 20 is defined as a reference line CL at each of the widthwise center and the lengthwise center, as shown in fig. 11, an elongated rectangle a is cut out in which two straight lines S1, S2 having a length of 1m parallel to the reference line CL are separated by 40mm intervals and both ends of the straight lines S1, S2 are connected by short lines T1, T2.
Then, after the resin component was removed by burning the cut pieces (10 pieces in total) of the rectangle a of each region having a size of 1m × 40mm cut out in the above manner, any of the short lines T1 and T2 (for example, T1) at both ends was sandwiched, and the carbon fiber bundle in the unconstrained state in the portion which was not sandwiched was shaken off. Next, the number N1 of carbon fiber bundles (warp yarns) in the sandwiched portion and the number N2 of carbon fiber bundles (warp yarns) remaining in the portion of the short yarn (T2) on the opposite side were counted, and the degree of collimation defined by the following formula was calculated based on N1 and N2.
(N2/N1)×100(％)
Such measurement and calculation are performed on the above ten slices, and the sum average of their ten degrees of collimation is taken as the degree of collimation R of the present invention.
The top plate 20 includes solid grip portions 23 protruding outward in the width direction and continuing in the longitudinal direction at both ends in the width direction, and the grip portions 23 are formed integrally with the fiber-reinforced resin. By forming the holding portions 23, both widthwise end portions of the top plate 20 form solid portions having a widthwise length W1 of 5mm to 30 mm. The thickness T of the solid portion is, for example, 4mm to 20 mm.
The top plate 20 is formed in a rectangular shape in plan view, but when applied to CT or X-ray imaging, it is preferably formed in a flat tubular shape in which the cross-sectional shape perpendicular to the longitudinal direction is curved into an arc shape for stably supporting a human body.
When the top plate 20 is viewed from above, the size is generally 190 to 350cm in the longitudinal direction and 35 to 50cm in the width direction.
In a cross section of the top plate 20 perpendicular to the longitudinal direction, upper sides of the outer plate 21 and the inner plate 22 are each bent in a concave arc shape, and form a crescent shape connecting both ends in the width direction. Further, caps are attached to both longitudinal ends of the top plate 20.
As shown in fig. 12, the outer panel 21 and the inner panel 22 are made of a fiber-reinforced resin obtained by inserting an all-carbon fiber fabric 25 made of carbon fiber bundles of warp and weft between two sheets of fabrics 24 and 24 each made of carbon fiber bundles having substantially no twist (twist of 5T/m or less) of warp, and curing the fabric by heating while impregnating the fabric with a thermosetting resin. The warp of the cord fabric 24 and the warp of the all-carbon fiber fabric 25 are respectively arranged in parallel in the length direction of the outer plate 21 and the inner plate 22, and the collimation degree R of the warp reaches more than 90%.
The fiber-reinforced resin constituting the outer panel 21 and the inner panel 22 is not limited to the laminate structure shown in fig. 12, and may be formed in the form shown in fig. 13. In the embodiment of fig. 13, a unidirectional carbon fiber sheet 26 is laminated on the outermost surface of the laminated structure of the carbon fiber fabric of fig. 12. Since the unidirectional carbon fiber sheet 26 does not include warp yarns, it is excellent in flatness and smoothness, and the top sheet 20 can have a better appearance by being disposed as the outermost layer.
The top plate 20 of the present invention may also be arranged with an all carbon fiber weave 25 as shown in fig. 14. In fig. 14, one all-carbon fiber fabric 25 is inserted between two sheets of the draperies 24, 24 constituting the inner panel 22. The all-carbon fiber fabric 25 is wider than the inner panel 22, and its wide end portions 25e and 25e are folded back toward the outer panel 21. In the outer panel 21, both end portions 25e, 25e of the all-carbon fiber fabric 25 are overlapped with each other with the two sheets of the fabrics 24, 24 interposed therebetween. The outer sheet 21 and the inner sheet 22 are each laminated with unidirectional carbon fiber sheets 26 at the outermost layer.
In the top plate 20 of fig. 14, the shape stability is improved by inserting the all-carbon fiber fabric 25, and warping or twisting is less likely to occur. Further, since both end portions 25e and 25e of the all-carbon fiber fabric 25 are folded so as to straddle between the inner panel 22 and the outer panel 21, the rigidity of the top panel 20 is improved. Also, by arranging the unidirectional carbon fiber sheet 26 at the outermost layer, the appearance is optimized.
In the top sheet 20 of the present invention, the degree of collimation R is 90% or more, preferably 95% or more, and thus the strength utilization rate of warp yarns in the carbon fiber woven fabric used as the main reinforcement can be improved, and as a result, the strength or rigidity (particularly, bending rigidity) of the top sheet 20 can be improved while the amount of carbon fibers used is reduced. Further, warping or twisting can be reduced, and the top plate 20 with excellent dimensional accuracy can be obtained. Further, the fiber content of the carbon fibers in the fiber-reinforced resin can be made 60% or more of the capacity that cannot be achieved by the conventional hand-held top sheet, and not only the strength and rigidity of the top sheet 20 can be improved, but also the X-ray transmittance of the top sheet 20 can be improved, and the photographed image can be made clearer.
The carbon fiber fabric used in the present invention uses a fabric in which at least warp yarns are carbon fibers, and preferably, carbon fiber bundles of warp yarns thereof are substantially untwisted carbon fiber bundles.
Preferably, the carbon fiber fabric used in the present invention is a cord fabric 24. The cord fabric 24 is characterized by having a weft density significantly lower than the warp density, and up to 5 threads/cm or more and 1 thread/cm or less, and more preferably, a cord fabric 24 having a weft density in the range of 0.2 to 0.5 threads/cm is used. If the density of weft is more than 1 weft/cm, the number of crimps per unit length (the number of bends of the wave form) formed on the warp yarn increases due to the crossing with the weft, resulting in a decrease in the strength utilization of the warp yarn. Further, if the weft density is less than 0.2 threads/cm, the effect of preventing the warp yarns from being cracked with each other is reduced, and the effect of uniformly arranging the warp yarns (uniform dispersion effect) is reduced.
The weft yarn used for the cord fabric 24 may be the same carbon fiber as the warp yarn, and preferably, an organic fiber is used. That is, the weft in the cord fabric 24 used in the present invention is used to maintain the reinforcing function of the carbon fiber fabric by suppressing the generation of cracks between the warp yarns adjacent to each other and suppressing the propagation and growth of such cracks, and therefore, may not have high strength or high elasticity. The organic fiber used for the weft is not particularly limited, and for example, polyamide fiber, polyvinyl alcohol fiber, polyester fiber, aramid fiber, or the like can be used.
Preferably, when the weft of the cord fabric 24 is made of organic fiber, the fiber fineness is in the range of 50 to 350 dtex. If the fineness is more than 350dtex, the carbon fiber of the warp yarn is largely curled, and thus the strength utilization rate is lowered. If the fineness is less than 50dtex, the effect of inhibiting the yarn breakage and imparting uniform dispersibility to the warp yarn is reduced.
Preferably, when the cord fabric 24 is used as a carbon fiber fabric, a plurality of the fabrics are stacked. In addition, when a plurality of sheets of the fabrics 24 are stacked, at least one sheet of the all-carbon fiber fabric 25 in which both warp yarns and weft yarns are made of carbon fibers is preferably inserted between any two sheets of the fabrics. By inserting the all-carbon fiber fabric 25, the shape stability of the top plate 20 can be improved, and the occurrence of warping or twisting can be suppressed.
Further, the all-carbon fiber fabric 25 inserted and disposed between the draperies 24 as described above is preferably disposed so as to extend across both width-direction end portions of the outer and inner panels 21 and 22 and be continuous between the two panels. By disposing across the outer panel 21 and the inner panel 22 as described above, the rigidity of the top panel 20 can be increased, and the shape stability can be improved. In addition, when the all-carbon fiber fabric 25 is inserted as described above, it is preferable that the all-carbon fiber fabric 25 having a width larger than the width of one of the outer panel 21 and the inner panel 22 is inserted into the other panel side toward the other panel side, and both end portions extending on both sides of the one panel are folded back to the other panel side to form a superimposed structure.
The structure of the all-carbon fiber fabric 25 used in combination with the cord fabric 24 is not particularly limited as long as both the warp and weft are made of carbon fiber bundles. Furthermore, the warp density and the weft density are preferably 5 threads/cm or more.
When the carbon fiber fabric is laminated in a plurality of layers, particularly when the cord fabric 24 is laminated in a plurality of layers, it is preferable to laminate the unidirectional carbon fiber sheet 26 on the surface of the outermost layer thereof. The unidirectional carbon fiber sheet 26 is mainly intended to optimize the appearance, and therefore may be a nonwoven fabric or paper made of organic fibers such as polyester fibers and nylon fibers.
The carbon fiber woven fabric, the unidirectional carbon fiber sheet 26, and the nonwoven fabric or paper made of organic fibers are formed into a fiber-reinforced resin by impregnating with a resin. The resin is preferably a thermosetting resin. In the present invention, as described above, since the strength utilization rate of the warp yarn in the carbon fiber fabric is improved, an unsaturated polyester resin, a vinyl ester resin, or the like may be used in addition to the epoxy resin.
Unsaturated polyester resins or vinyl ester resins can easily impart flame retardancy as compared to epoxy resins. Further, the unsaturated polyester resin or vinyl ester resin can easily realize low shrinkage compared to the epoxy resin, and a top sheet having more excellent dimensional stability can be obtained.
A method for manufacturing the top plate (cylindrical body) 20 shown in fig. 7 and 8 by the manufacturing method of the present invention will be described below. The manufacturing method of the present invention uses drawing and can efficiently and continuously manufacture the top plate 20.
As illustrated in fig. 1, in the manufacturing process, a plurality of rollers 18 of the reinforcing sheet are supported on the creel, and a stopper is attached to a support shaft of the creel. This applies a braking force to the reinforcing sheet drawn out from each roller 18.
One of the two roller 18 groups (lower side in fig. 1) is provided with a reinforcing sheet group for forming the outer sheet 21, and therefore, there are provided two rollers 18 for winding a cord fabric 24 made of carbon fibers and one roller 18 for winding a unidirectional carbon fiber sheet 26. Both the cord fabric 24 and the unidirectional carbon fiber sheet 26 are formed to have substantially the same width as the outer panel 21. The warp of the cord fabric 24 is substantially untwisted carbon fiber bundles, and the weft uses organic fibers such as polyamide fibers, and the density of the weft is 1 piece/cm or less.
The other roller 18 group (upper side in fig. 1) is provided with a reinforcing sheet group for forming the inner panel 22, and is provided with two rollers 18 for winding a cord fabric 24 made of carbon fiber, one roller for winding an all-carbon fiber fabric 25, and one roller 18 for winding a unidirectional carbon fiber sheet 26. The shade fabric 24 is formed of the same construction as the shade fabric 24 provided on one set of rollers 18. The cord fabric 24 and the unidirectional carbon fiber sheet 26 are formed to have the same width as the inner panel 22, and the full carbon fiber fabric 25 has a width twice or more the width of the inner panel 22.
First, according to the drawing operation of the drawing device 5, the reinforcing sheet group of the tire cord fabric 24, the all-carbon fiber fabric 25, and the unidirectional carbon fiber sheet 26 drawn out from the respective roller 18 groups while being braked passes through the resin liquid tanks 2, and is applied with the uncured thermosetting resin liquid.
Then, the shade fabric 24 on the side of the roller 18 group is brought close to the surface (lower side in fig. 1) of the core 4a by the guide portion 14 a. Then, the wide all-carbon fiber fabric 25 drawn out from the other roller 18 group is folded downward at both ends thereof by the folding guide 14c and is overlapped on the surface of the cord fabric 24 which is initially adjacent to the surface of the core 4a (the lower side surface in fig. 1) by the guide 14 b.
Then, at the inlet of the impregnation treatment section 3, the cord fabric 24 and the unidirectional carbon fiber sheet 26 on the side of the set of one rollers 18 are superposed on the folded portion of the all-carbon fiber fabric 25 with the cord fabric 24 side as the inner side. Further, the reinforcing sheet group of the cord fabric 24, the all-carbon fiber fabric 25, and the unidirectional carbon fiber sheet 26 of the other side roller 18 group is disposed adjacent to the opposite side (upper side in fig. 1) of the core 4 a.
The penetration treatment section 3 is composed of an upper mold and a lower mold, and a space having a crescent-shaped cross section is formed inside the penetration treatment section so as to linearly penetrate in front and rear. By penetrating the core 4a in this space, an annular drawing gap is formed around the core 4 a. The drawing gap has a gap width slightly larger than that of the forming gap of the downstream forming die 4.
The impregnation processing section 3 impregnates the resin solution into the respective interiors of the fabric 24, the all-carbon fiber fabric 25, and the unidirectional carbon fiber sheet 26, to which the resin solution has been adhered in the resin solution tanks 2, when passing through the drawing gap along the surface of the core 4 a. Further, on the exit side of the treated part 3, the sheet 24, the all-carbon fiber fabric 25, and the unidirectional carbon fiber sheet 26 are preliminarily formed into a laminated state having a crescent-shaped cross section. In this preforming, since the cord fabric 24 and the all-carbon fiber fabric 25 have the weft, the weft applies a lateral shift resistance to the warp group to be uniformly distributed in the width direction, and is aligned in parallel in the longitudinal direction by the drawing operation of the drawing device 5.
The molding die 4 is composed of an upper die 4 and a lower die, as in the case of the impregnation treatment section 3, and has a heating device (heater) incorporated therein, and a space having a crescent-shaped inner cross section extends through the front and rear portions in a straight line. By passing the core 4a through this space, an annular forming gap is formed around the core 4 a. The core 4a penetrates the molding die 4, and the tip thereof reaches a position slightly beyond the downstream end surface of the molding die 4.
In the forming die 4, a laminate of a cord fabric 24, an all-carbon fiber fabric 25, and a unidirectional carbon fiber sheet 26, which are preliminarily formed to have a crescent cross section, is passed through a forming gap so as to be close to the core 4a, drawn by the drawing device 5, and heated and cured by a heater, thereby forming a flat cylindrical intermediate formed body 15 having a crescent cross section as shown in fig. 3 and 4.
In this way, a long carbon fiber woven fabric in which at least warp yarns are carbon fibers and an uncured resin is impregnated is inserted into the forming gap of the forming die 4, and the fabric is sequentially drawn from the upstream side to the downstream side by a predetermined length while applying tension. Thus, the cylindrical intermediate formed body 15 in which the outer panel and the inner panel are arranged facing each other with a space therebetween and both ends in the width direction are connected to each other is formed and heat cured. The intermediate formed body 15 has grip portions 23, 23 formed integrally at both ends in the width direction 15, protruding outward in the width direction and continuing in the longitudinal direction.
In the forming, the tension of the carbon fiber web before insertion into the forming gap is preferably 5N/mm2Above 980N/mm2The following. That is, the tension of the cord fabric 24, the all-carbon fiber fabric 25, and the unidirectional carbon fiber sheet 26 on the inlet side of the forming die 4 may be 5 to 980N/mm2Preferably 10 to 490N/mm2More preferably 10 to 300N/mm2. By applying such tension, the carbon fiber bundles in the cord fabric 24, the all-carbon fiber fabric 25, and the unidirectional carbon fiber sheet 26, which are pre-formed in the impregnation treatment section 3 in a crescent shape in cross section, can be aligned straight between the impregnation treatment section 3 and the forming die 4, and the degree of alignment R of the warp yarn when applied to the top sheet 20 can be 90% or more.
When the screen cloth 24, the all-carbon fiber fabric 25, and the unidirectional carbon fiber sheet 26 are first set in the penetration treatment section 3 and the forming mold 4, the setting can be easily performed when the core 4a is pulled out from the forming mold 4 and the penetration treatment section 3 to the upstream side, and the core 4a is inserted after the screen cloth 24, the all-carbon fiber fabric 25, and the unidirectional carbon fiber sheet 26 pass through the space passing through the forming mold 4 and the penetration treatment section.
The drawing device 5 is used for continuously drawing the solidified intermediate formed body 15, and by the drawing operation, a large tension is generated on the cord fabric 24, the all-carbon fiber fabric 25, and the unidirectional carbon fiber sheet 26 on the upstream side of the forming die 4, and the warp yarns extending in the longitudinal direction and the like are aligned straight.
As illustrated in fig. 2 to 4, the drawing device 5 arranges a pair of sliders 5a and 5b at intervals in the moving direction of the intermediate formed body 15. Each of the sliders 5a and 5b includes a moving roller 13a on the bottom surface of the lower plate 10, and the upstream slider 5a reciprocates between the upstream half strokes and the downstream half strokes of the chassis 13 about a longitudinal midpoint thereof.
Each slider 5a, 5b is provided with four posts 8 standing on a lower plate 10, and a holding plate 7 is fixed to the upper end of each post 8. An up-and-down movement cylinder 6 is mounted on the holding plate 7, and an upper plate 9 is attached to the front end of a cylinder rod extending downward. Four pillars 8 are penetrated in the upper plate 9, and the upper plate 9 is moved up and down by the up-and-down movement of the up-and-down movement cylinder 6.
An upper holding die 11 is attached to the lower surface of the upper plate 9, and a lower holding die 12 is attached to the upper surface of the lower plate 10. The lower surface of the upper holding die 11 has a circular-arc cross-sectional shape substantially equal to the outer shape of the solidified intermediate formed body 15 on the inner panel side (upper side in fig. 3 and 4). The cross-sectional shape of the upper surface of the lower holding die 12 is formed into an arc shape substantially identical to the outer shape of the outer plate side (lower side in fig. 3 and 4) of the solidified intermediate formed body 15.
The upper and lower pair of holding dies 11 and 12 have arc-shaped surfaces arranged to face each other. By the action of the up-down moving cylinder 6, the upper holding die 11 moves closer to the lower holding die 12 and moves away from the lower holding die 12. Thus, when the upper holding die 11 and the lower holding die 12 are combined while being in contact with each other, a crescent space having substantially the same cross section as the solidified intermediate formed body 15 is formed by the inner surfaces of the pair of upper and lower holding dies 11 and 12.
In the drawing operation, first, as shown in fig. 5, the upper holding die 11 attached to the upstream slider 5a is moved downward, and the inner surfaces of the upper and lower pair of holding dies 11, 12 are brought into contact with the surface of the solidified intermediate formed body 15 so as to be annularly covered with the inner surfaces of the upper and lower pair of holding dies 11, 12, and the solidified gripping portions 23, 23 are sandwiched by the upper and lower pair of holding dies 11, 12, whereby the gripping portions 23, 23 are compressed.
At this time, the surface of the hollow portion of the intermediate formed body 15 is only slightly in contact with the inner surfaces of the pair of upper and lower holding dies 11 and 12, and is in a state of being substantially not subjected to pressure. In this state, the slider 5a is moved to the downstream side by a predetermined length. For example, the downstream end of the slider 5a is moved to the middle point in the front-rear direction of the base 13.
The compression force of the vertical movement cylinder 6 for moving the upper holding die 11 downward is, for example, about 2200kgf, and the average pressure calculated by dividing the compression force by the area of the upper holding die 11 (lower holding die 12) in the plan view in contact with the intermediate formed body 15 is 12 × 104Pa～15×104Pa(1.2kgf/cm2～1.5kgf/cm2) Left and right. In fact, since the pressure acting on the gripping portions 23, 23 is greater than that of the other portions, the gripping portions 23, 23 are compressed by a pressure greater than the average pressure.
When the slider 5a on the upstream side moves as described above, the upper holding die 11 attached to the slider 5b on the downstream side is moved upward, and the gripping portions 23, 23 cured by the pair of upper and lower holding dies 11, 12 of the slider 5b are not sandwiched. In this state, the slider 5b is moved to the upstream side by a predetermined length. For example, the upstream end of the slider 5b is moved to the middle point in the front-rear direction of the base 13.
The operation of the upstream slider 5a and the downstream slider 5b is the first moving step. By the operation of the upstream slider 5a in the first moving step, a new carbon fiber cloth impregnated with uncured thermosetting resin liquid is inserted into the drawing gap of the impregnation treatment section 3 and the molding gap of the molding die 4, and is drawn from the upstream side to the downstream side by a predetermined length while applying tension.
And executing a second moving process after the first moving process. First, as shown in fig. 6, the upper holding die 11 of the downstream slider 5b is moved downward, the inner surfaces of the upper and lower pair of holding dies 11, 12 are brought into contact with the surface of the solidified intermediate formed body 15 so as to be annularly covered with the inner surfaces of the upper and lower pair of holding dies 11, 12, and the solidified gripping portions 23, 23 are sandwiched by the upper and lower pair of holding dies 11, 12, whereby the gripping portions 23, 23 are compressed. At this time, the surface of the hollow portion of the intermediate formed body 15 is only slightly in contact with the inner surfaces of the pair of upper and lower holding dies 11 and 12, and is substantially in a state of not receiving a pressure. In this state, the slider 5b is moved to the downstream side by a predetermined length. For example, the downstream end of the slider 5b is moved to the end of the base 13 in the front-rear direction.
When the downstream slider 5b moves as described above, the upper holding die 11 attached to the upstream slider 5a is moved upward, and the solidified gripping portions 23 and 23 are thereby placed in a state where they are not sandwiched between the pair of upper and lower holding dies 11 and 12 of the slider 5 a. In this state, the slider 5a is moved by a predetermined length toward the upstream side. For example, the upstream end of the slider 5b is moved to the end of the base 13 in the front-rear direction.
The operation of the upstream slider 5a and the downstream slider 5b described above is the second moving step. By the operation of the downstream-side slider 5b in the second moving step, a new carbon fiber woven fabric into which uncured thermosetting resin liquid has been impregnated is inserted into the drawing gap of the impregnation treatment section 3 and the molding gap of the molding die 4, and is drawn from the upstream side toward the downstream side by a predetermined length while applying tension. In this case, the drawing speed is, for example, about 0.2 m/min to 0.5 m/min.
The first moving step and the second moving step are alternately performed, and a new carbon fiber woven fabric into which uncured thermosetting resin liquid has been impregnated is inserted into the drawing gap of the impregnation treatment section 3 and the molding gap of the molding die 4, and is drawn in order from the upstream side to the downstream side by a predetermined length while applying tension.
In this way, the intermediate formed body 15 formed and solidified by being drawn through the forming gap of the forming die 4 is sequentially conveyed to the downstream side, and is conveyed to the heating furnace 16 through the first moving step and the second moving step by the drawing device 5. The heating furnace 16 is not particularly limited, and any known one may be used. The intermediate formed body 15 solidified by the forming die 4 is reheated in the heating furnace 16 to perform finishing treatment to substantially complete the solidification of the intermediate formed body 15 and to remove internal strain to stabilize the shape.
The finished intermediate formed bodies 15 are sequentially conveyed to the downstream side, cut into a predetermined length by a cutter 17, and carried out by a conveying conveyor. The intermediate formed body 15 cut to a predetermined length is formed as a top plate 20 and is fitted with a lid at both longitudinal ends.
In the present invention, when the cylindrical intermediate formed body 15 is formed, the solid gripping portions 23, 23 that protrude outward in the width direction and are continuous in the longitudinal direction are integrally formed at both ends in the width direction. Thus, the solidified gripping portions 23, 23 can be firmly clamped by the pair of upper and lower holding dies 11, 12 attached to the sliders 5a, 5b of the drawing device 5. Thus, the hollow-formed portion of the solidified intermediate formed body 15 is not subjected to an excessive pressure, and can be held by applying a sufficiently large pressure only to the solid gripping portions 23, 23 to perform the drawing operation.
Therefore, the hollow portion of the intermediate formed body 15 does not need to be held by the pair of upper and lower holding dies 11 and 12, and the thickness of the intermediate formed body 15, particularly the top plate 20, can be minimized. Thus, when the manufactured top plate 20 is applied to a CT or a general X-ray radiography top plate, the transmission loss of X-rays can be reduced. Thus, accurate image data can be obtained, and more accurate and clear image photographing can be realized.
Since air is also discharged from the drawing gap in which the penetration processing portion 3 and the forming gap in the forming die 4 penetrate, the inserted member is drawn so as to be drawn. Therefore, although the drawing work requires a drawing force of a certain degree or more, according to the present invention, the solidified gripping portions 23, 23 can be sandwiched by the pair of upper and lower holding dies 11, 12 with a large pressure, and therefore the drawing force can be increased as compared with the conventional one, and therefore the drawing work is facilitated. Meanwhile, the degree of collimation of the warp of the carbon fiber fabric can be easily improved to over 90%, which is beneficial to improving the strength of the manufactured top plate 20.
In order to firmly and stably clamp and compress the gripping portion 23 by the pair of upper and lower holding dies 11 and 12, the length in the width direction of the solid portion formed at both ends in the width direction of the intermediate formed body 15 (top plate 20) is preferably 1.0% to 8%, more preferably 1.0% to 6.5% of the width of the intermediate formed body 15 (top plate 20).
When the pair of upper and lower holding dies 11 and 12 attached to the sliders 5a and 5b are brought into contact and combined, it is preferable that the height of the space at both ends in the width direction (corresponding to the space of the gripping portions 23 and 23) in the space formed by the inner surfaces of the pair of upper and lower holding dies 11 and 12 be set to 80% to 90% of the thickness of the cured gripping portions 23 and 23. This makes it possible to easily hold only the solid gripping portions 23 and 23 by applying a sufficiently large pressure without applying an excessive pressure to the hollow-formed portion of the solidified intermediate formed body 15.
Fig. 9 illustrates another embodiment of the cartridge of the present invention. This embodiment is different from the embodiment illustrated in fig. 7 and 8 only in the specification of both ends in the width direction, and since other specifications are the same, only the difference will be described.
In this embodiment, the grip portion 23 is removed by cutting both ends in the width direction of the top plate 20 shown in fig. 7 and 8 with a cutting device. That is, the intermediate formed body 15 is moved to the downstream side while being sandwiched and compressed by the pair of upper and lower holding dies 11 and 12 attached to the sliders 5a and 5b of the drawing device 5, and thereafter, the gripping portions 23 and 23 sandwiched by the pair of upper and lower holding dies 11 and 12 are cut.
The length W2 of the solid portion at both ends of the top plate 20 is about 2mm to 7mm by the cutting process. This has an advantage that when used as the CT top 20, artifacts can be reduced.
The artifact is a phenomenon that occurs due to a difference in total thickness of the top plate 20 (the outer plate 21 and the inner plate 22) through which X-rays that travel in a straight line according to a difference in circumferential position pass when a subject above the top plate 20 is imaged from the outer peripheral side over the entire circumference in the circumferential direction. That is, at a circumferential position where the total thickness of the top plate 20 (the outer plate 21 and the inner plate 22) through which the linearly advancing X-rays pass is large, the transmission loss of the X-rays is large, and a part of the top plate 20 is imaged as a virtual image. Therefore, if the both ends in the width direction of the top plate 20 have a solid portion like the grip portion 23, the X-ray loss at a certain circumferential position becomes large, the virtual image is easily imaged, and it is difficult to realize precise imaging.
According to the top plate 20 of fig. 9, although the adverse effect of the artifact can be reduced, the strength of the top plate 20 is somewhat reduced because the weft of the carbon fiber fabric is cut. Therefore, as illustrated in fig. 10, the portion where the grip portion 23 is cut may be reinforced by a reinforcement 23a made of a fiber-reinforced resin that is attached later. The reinforcement 23a may use the same specification of fiber reinforced resin applied to the top panel 20, and may also use different specifications of fiber reinforced resin.
The thickness of the reinforcement 23a is about 0.5mm to 1.0mm, and is smaller than the width of the grip 23 when cut. This can increase the strength of the top plate 20 and reduce the adverse effect of artifacts.
Since the CT top board 20 has a large limitation in size, the embodiment of fig. 9 and 10 is very advantageous.
The tubular body of the present invention can be applied to CT or a general top plate for X-ray radiography, and can be exemplified by a housing case for housing a film for sensing X-rays transmitted through a human body at the time of X-ray radiography. Such a film is provided with an element capable of sensing X-rays, and image data is created based on the sensed data of the element, and the X-ray image is displayed on a display.
Claims (12)
1. A method for manufacturing a tubular body made of fiber-reinforced resin, characterized in that a core is inserted into a space linearly penetrating through a forming die, a long carbon fiber woven fabric in which at least warp yarn is carbon fiber and which is impregnated with uncured resin is inserted into a tubular forming gap formed between the forming die and the core, and a tubular intermediate formed body which is provided with an outer plate and an inner plate facing each other with a gap therebetween and connects both end portions in a width direction of each other is formed by drawing a predetermined length from an upstream side to a downstream side in sequence while applying tension, and after heat-curing the intermediate formed body, the cured intermediate formed body is conveyed to the downstream side in sequence and cut into a predetermined length to manufacture a tubular body, and a degree of collimation R of the warp yarn, which is defined with a center line passing through a center in a width direction of the tubular body, is 90% or more, wherein,
in the molding of the intermediate molded body, solid grip portions are integrally formed at both widthwise end portions of the intermediate molded body so as to protrude outward in the widthwise direction and be continuous in the lengthwise direction, inner surfaces of a pair of upper and lower holding dies are brought into contact with a surface of the intermediate molded body so as to cover the surface of the solidified intermediate molded body, the pair of upper and lower holding dies are moved to the downstream side by a predetermined length in a state where the solidified grip portions are compressed by being sandwiched by the pair of upper and lower holding dies, and a new carbon fiber woven fabric is inserted into the molding gap and is drawn from the upstream side to the downstream side by the predetermined length while applying tension.
2. The method of manufacturing a cylindrical body made of a fiber-reinforced resin according to claim 1, wherein the solidified gripping portion is moved to a downstream side by a predetermined length while being sandwiched and compressed by a pair of upper and lower holding dies, and thereafter the gripping portion sandwiched by the pair of upper and lower holding dies is cut.
3. The method of manufacturing a cylindrical body made of fiber-reinforced resin according to claim 2, wherein the portion where the grip portion is cut is reinforced by a reinforcing member made of fiber-reinforced resin.
4. The method of manufacturing a fiber-reinforced resin tubular body according to any one of claims 1 to 3, wherein two of the upper and lower pair of holding dies are arranged at an interval in the direction of movement of the intermediate formed body, and a first moving step and a second moving step are alternately performed to insert a new carbon fiber woven fabric into the forming gap and draw a predetermined length from the upstream side toward the downstream side in order while applying tension, wherein in the first moving step, the intermediate formed body is moved downstream by a predetermined length in a state where the cured gripping portions of the intermediate formed body are sandwiched and compressed by the upper and lower pair of holding dies on the upstream side, and is moved upstream by a predetermined length in a state where the cured gripping portions of the intermediate formed body are not sandwiched by the upper and lower pair of holding dies on the downstream side, and in the second moving step, next to the first moving step, the intermediate formed body is moved by a predetermined length toward the downstream side while the solidified gripping portions of the intermediate formed body are sandwiched and compressed by the pair of upper and lower holding dies on the downstream side, and is moved by a predetermined length toward the upstream side while the solidified gripping portions of the intermediate formed body are not sandwiched by the pair of upper and lower holding dies on the upstream side.
5. The method of manufacturing a fiber-reinforced resin cylindrical body according to any one of claims 1 to 4, wherein the tension of the carbon fiber fabric inserted into the forming gap is 5N/mm2Above 980N/mm2The following.
6. A fiber-reinforced resin tubular body comprising an outer plate and an inner plate which are arranged in a face-to-face manner with a long distance therebetween and which are connected to each other at both ends in a width direction, wherein the outer plate and the inner plate are made of a fiber-reinforced resin comprising a carbon fiber fabric as a main reinforcement, at least warp yarns are carbon fibers, and the warp yarns are linearly arranged in parallel in a longitudinal direction of the outer plate and the inner plate, respectively, and wherein a degree of collimation R of the warp yarns is 90% or more based on a center line passing through a center in the width direction of the tubular body,
the cylindrical body has solid grip portions protruding outward in the width direction and continuing in the longitudinal direction at both ends in the width direction, the grip portions are integrally formed by the fiber-reinforced resin, and the cylindrical body has solid portions formed at both ends in the width direction, the solid portions having a length in the width direction of 1.0% to 8.0% of the width of the cylindrical body.
7. A fiber-reinforced resin tubular body comprising an outer plate and an inner plate which are arranged in a face-to-face manner with a long distance therebetween and which are connected to each other at both ends in a width direction, wherein the outer plate and the inner plate are made of a fiber-reinforced resin comprising a carbon fiber fabric as a main reinforcement, at least warp yarns are carbon fibers, and the warp yarns are linearly arranged in parallel in a longitudinal direction of the outer plate and the inner plate, respectively, and wherein a degree of collimation R of the warp yarns is 90% or more based on a center line passing through a center in the width direction of the tubular body,
the cylindrical body has both ends in the width direction formed by cutting a solid grip portion integrally formed in advance of the fiber-reinforced resin and projecting outward in the width direction and continuing in the longitudinal direction.
8. The cylindrical body made of fiber reinforced resin according to claim 7, wherein a portion of the grip portion subjected to the cutting process is reinforced by a reinforcing member made of fiber reinforced resin.
9. The cylindrical body made of fiber-reinforced resin according to any one of claims 6 to 8, wherein the carbon fiber woven fabric is a cord fabric having a weft density of 1 piece/cm or less, and the weft of the cord fabric is made of an organic fiber having a weft density of 50dtex or more and 350dtex or less.
10. The cylindrical body made of fiber-reinforced resin according to claim 9, wherein a plurality of the fabrics are stacked, and an all-carbon fiber fabric made of carbon fibers in both warp and weft is inserted between any two fabrics.
11. The fiber-reinforced resin tubular body according to claim 10, wherein the all-carbon fiber fabric is provided so as to straddle both sides of the outer plate and the inner plate.
12. The fiber-reinforced resin tubular body according to claim 11, wherein the all-carbon fiber fabric having a wider width than the outer plate is inserted into one of the outer plate and the inner plate, and both ends of the all-carbon fiber fabric are folded back onto the other plate side.
Applications Claiming Priority (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| PCT/JP2009/051891 WO2010089863A1 (en) | 2009-02-04 | 2009-02-04 | Process for producing tubular structure made of fiber-reinforced resin and tubular structure made of fiber-reinforced resin |
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| Publication Number | Publication Date |
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| CN102282007A true CN102282007A (en) | 2011-12-14 |
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| CN2009801548415A Pending CN102282007A (en) | 2009-02-04 | 2009-02-04 | Process for producing tubular structure made of fiber-reinforced resin and tubular structure made of fiber-reinforced resin |
Country Status (3)
| Country | Link |
|---|---|
| JP (1) | JP4827206B2 (en) |
| CN (1) | CN102282007A (en) |
| WO (1) | WO2010089863A1 (en) |
Cited By (3)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| CN106687268A (en) * | 2014-09-25 | 2017-05-17 | 东丽株式会社 | Method for manufacturing reinforced fiber sheet |
| CN109153794A (en) * | 2016-05-27 | 2019-01-04 | 三菱瓦斯化学株式会社 | Material and molded product |
| CN112996653A (en) * | 2019-03-08 | 2021-06-18 | 株式会社Ihi空间技术 | FRP forming system and method |
Families Citing this family (2)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| DE102012018429A1 (en) * | 2012-06-20 | 2013-12-24 | Thomas Gmbh + Co. Technik + Innovation Kg | Method and device for producing a hollow plastic article having at least one transverse reinforcement |
| JP2018051000A (en) * | 2016-09-29 | 2018-04-05 | 東レ株式会社 | Top board for radiology equipment and x-ray ct apparatus |
Family Cites Families (4)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| JPS60236634A (en) * | 1984-05-10 | 1985-11-25 | 三菱レイヨン株式会社 | Top plate for radiation diagnostic apparatus |
| JPS6335334A (en) * | 1986-07-31 | 1988-02-16 | Showa Highpolymer Co Ltd | Molding method for hollow plastic product composed of fiber-reinforced material |
| JP4162916B2 (en) * | 2002-05-01 | 2008-10-08 | サカイ・コンポジット株式会社 | Top plate for X-ray machine and method for manufacturing the same |
| JP2007020986A (en) * | 2005-07-20 | 2007-02-01 | Toray Ind Inc | Top board for medical radiological equipment and x-ray ct apparatus |
-
2009
- 2009-02-04 JP JP2010549303A patent/JP4827206B2/en active Active
- 2009-02-04 CN CN2009801548415A patent/CN102282007A/en active Pending
- 2009-02-04 WO PCT/JP2009/051891 patent/WO2010089863A1/en active Application Filing
Cited By (6)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| CN106687268A (en) * | 2014-09-25 | 2017-05-17 | 东丽株式会社 | Method for manufacturing reinforced fiber sheet |
| CN106687268B (en) * | 2014-09-25 | 2020-01-17 | 东丽株式会社 | Reinforced fiber sheet manufacturing device |
| CN109153794A (en) * | 2016-05-27 | 2019-01-04 | 三菱瓦斯化学株式会社 | Material and molded product |
| CN109153794B (en) * | 2016-05-27 | 2021-04-09 | 三菱瓦斯化学株式会社 | Material and molded article |
| CN112996653A (en) * | 2019-03-08 | 2021-06-18 | 株式会社Ihi空间技术 | FRP forming system and method |
| CN112996653B (en) * | 2019-03-08 | 2022-11-29 | 株式会社Ihi空间技术 | FRP forming system and method |
Also Published As
| Publication number | Publication date |
|---|---|
| JP4827206B2 (en) | 2011-11-30 |
| JPWO2010089863A1 (en) | 2012-08-09 |
| WO2010089863A1 (en) | 2010-08-12 |
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Application publication date: 20111214 |